Microwave cable assemblies

Microwave cable assemblies Edition 2022 hubersuhner.com

Create reliability and high performance

Your partner for system solutions HUBER+SUHNER makes a significant contri- bution to simpli-fying processes by supplying cables assembled with connector according to customer requirements. The assemblies are manufactured using high-quality cables and connectors, carefully tested according to the relevant standards and delivered with a cer- tificate upon request. 3

Content General assembly information 6 Qualified, high performance 10 microwave cable assemblies > SUCOFLEX 100/200/300 /500 Qualified, low profile, high performance 87 microwave cable assemblies > Minibend family Microwave test cable assemblies 117 > Sucotest/TL-8A/TL-P Flexible microwave cable assemblies 131 > Boa-flex/Steel-flex/Multiflex/S-Series Formstable and handformable 167 microwave cables assemblies > Sucoform/SPJ/Cobra-flex/Semi-rigid Constant over Temperature (CT line) - 186 Dielectric core technology for best phase stability vs. Temperature Engineering information 191 Selection guide 201 5

General assembly information Cables and connectors from the same manufacturer HUBER+SUHNER develops and manufactures coaxial cables and connectors for most applications and in a multitude of versions. The connector series comprise over 1700 different types which prove their qualities daily worldwide. Demanding customers trust the reliability and quality of HUBER+SUHNER products. These products have been tested to IEC, MIL, CECC and other standards. Our extensive know-how in RF technology enables reliable and competent technical consulting and support. You stand to benefit from a well matched cable and connector range as well as many years vast experience of our engineers. Microwave cable assemblies to your specifications Make use of the HUBER+SUHNER custom design service. Increase efficiency and productivity in your company by ordering ready-to-use microwave cable assemblies from the specialists. Expert assembly by soldering, clamp or crimp technique and inspection records according to your specifications enable you to order with confidence. Advantages of microwave cable assemblies Purchasing of ready-made microwave cable assembly lines provides important benefits: • Perfect assembly, no rejects • No need for training assembly personnel • No capital investment for assembly provisions • Precisely matched cables and connectors from the same manufacturer • HUBER+SUHNER guaranties quality 6

General assembly information Assembly shop capability Automatic bending Automatic stripping Automatic laser stripping Temperature controlled soldering Clean room Laser marking 7

General assembly information Length definition and assembly design The assembly lengths are measured using the connector reference plane of straight plug and jack connectors and the pin centerline of right angle connectors. D-shape flat Assembly length Assembly length Standard assembly length tolerances SUCOFLEX®, Sucotest Minibend Multiflex and S-series ≤ 200 mm ± 1.0 mm ± 7.1 mm ≤ 500 mm ± 5.0 mm > 200 mm ± 0.5 % ≤ 1000 mm ± 7.0 mm ≤ 2000 mm ± 12.0 mm > 2000 mm ± 0.6 % Sucoform Semi-rigid, Boa-flex, Ever-flex, Steel-flex, Cobra-flex ≤ 500 mm ± 3.0 mm ≤ 500 mm ± 2.0 mm ≤ 1000 mm ± 5.0 mm ≤ 1000 mm ± 3.0 mm ≤ 2000 mm ± 8.0 mm ≤ 2000 mm ± 5.0 mm > 2000 mm ± 0.4 % > 2000 mm ± 0.3 % Tighter assembly tolerances are available on special request. Please ask your local HUBER+SUHNER partner. Angular displacement and D-shape flat of connectors Connector A With HUBER+SUHNER microwave cable assemblies that 0° Displacement angle have right angle or right angle and bulkhead connec- between connectors tors the relative angular displacement must be speci- fied as shown in the following sketches. 270° 90° Connector B 180° Connector B 0° D-shape flat 90° Connector A D-shape flat 8 Connector reference Connector reference Reference direction

General assembly information Care and handling instructions HUBER+SUHNER microwave cable assemblies of all types offer a long service life providing they are treated with the appropriate care and attention. Microwave cable assemblies are high precision system components and require proper handling in order to ensure that measured performance values are maintained. To achieve the maximum installed performance the following guidelines should be followed: 1. A ssemblies should remain in their original packaging for delivery and storage. Storage temperature should be between −50 and +80 °C and the relative humidity should not exceed 85 %. 2. Carefully unpack assemblies before installation. Avoid kinking cables when straightening from a coil or reel. 3. E nsure that the surroundings are clean and free of dust, dirt and any other particles that could enter un- sealed connector interfaces. 4. Use protective caps to prevent contamination whenever connectors are unmated. 5. W here interfaces are contaminated, particles can be removed with dry, oil-free compressed air. Please use eye-protection. Interfaces can be cleaned with dry cotton swabs. Do not use hard handtools or solvents. Do not blow into interfaces or use normal compressed-air. 6. C hoose the installation routing using the largest bend radii possible. Small bend radii may affect electrical performance. Exceeding the specified limits during the installation process could cause a permanent degra- dation. 7. Avoid twisting microwave cable assemblies. Torsion of this type of assembly can alter the relative diameters of cable layers and affects the electrical characteristics. Exceeding the limit of 10° per metre during installa- tion process could cause a permanent degradation. 8. Assemblies should be fixed in place without excess pressure. The use of cable ties should be avoided where possible, as they can easily exert more force than this. If cable ties must be used then they should be as wide as possible and still allow movement of the cable. Avoid placing fixings at regular intervals. 9. Examine interfaces for damage and/or contamination before mating. 10. Discharge connectors before mating or ensure that they are connected to a suitable ground. 11. When mating connectors with a screwed interface always hold the connector bodies and turn only the cou- pling nut. This avoids twisting the cable and ensures minimum wear on the connector pins. 12. Do not exceed the specified torque. 9

Qualified, high performance microwave cable assemblies The flexible SUCOFLEX® series microwave cable assemblies offer superior electrical and mechanical performance for static and dynamic applications. This series is a high-end product designed to provide optimal performance up to 50 GHz, where stringent electrical requirements, in particular electrical stability and low loss, are important. Ideally suited for test and measurement applications and defense sys- tems. Additional lightweight high end versions are designed to meet the stringent needs of space flights systems (i. e. satellites) and aerospace systems (aircrafts, helicopters, missiles), which are subject to extremely severe operating conditions. SUCOFLEX is only available as assembly. 1 0

SUCOFLEX® • Introduction • Advantages • Overview • Qualifications SUCOFLEX 100 The low loss, high performance microwave cable assembly • For static and dynamic applications up to 50 GHz • Excellent return loss • A balanced range of connectors is available, including types which feature NWA–specific interfaces, and can be provided with various ruggedisations to protect the assembly against dif- ferent environmental influences • Stock assemblies available SUCOFLEX 200 The loss revolution for dynamic applications • For static and dynamic applications up to 40 GHz • Ultra low loss • Outstanding phase stability vs. temperature • Excellent return loss • Stock assemblies available SUCOFLEX 300 The light weight, low loss microwave cable assemblies • SUCOFLEX 300 series offers a consistently outstanding mechanical and electrical performance, stability and reliability up to 40 GHz • Weight reduction of up to 40 % compared to our conventional products • Assemblies produced in a clean environment room SUCOFLEX 500 When it comes to test and measurement, SUCOFLEX 500 assemblies guarantee the highest level of satisfaction • Torque, crush and kink resistant • Precise and repeatable measurements • L ong service life • R educe total cost of test with durable, reliable performance • Increased test and measurement efficiency saving costs due to reduced calibration intervals 1 1

Introduction SUCOFLEX® What are SUCOFLEX assemblies? The assembly lengths are measured using the connector reference plane of straight plug and jack connectors and the pin centerline of right angle connectors. SUCOFLEX are flexible microwave cable assemblies offering better transmission characteristics than semi-rigid cables. SUCOFLEX comprises an entire system of optimally matched components such as: • Microwave cables • Connectors • Ruggedisations • Marking sleeves • ... SUCOFLEX is manufactured by highly qualified HUBER+SUHNER employees and tested against strict quality standards under controlled conditions. This results in microwave cable assemblies meeting all of your needs for top quality and high precision reproducibility. SUCOFLEX is always supplied as a complete, tested microwave cable assembly with defined and guaranteed radio fre- quency and mechanical values. SUCOFLEX is defined in the following way: One standard assembly consists of the following items if no additional specifications are provided: • Microwave cable specified • Connectors specified • Marking sleeve with serial number • RF test protocol showing insertion and return losses SUCOFLEX provides an optimum solution to your microwave transmission problems. SUCOFLEX cables, connectors and assemblies are entirely developed, manufactured, tested and supplied by HUBER+SUHNER, your partners for flexible microwave cable assemblies. SUCOFLEX is a registered trade mark for microwave cable assemblies from HUBER+SUHNER AG. 1 2

Advantages of SUCOFLEX® Test+Measurement Wide range of connectors and ruggedisation PC 2.4, PC 3.5, SK, SMA, BMA, QMA, QN, BNC, TNC, N, PC7 and various ruggedisations Electrical stability Thanks to their special design, types like SUCOFLEX 550, SUCOFLEX 102, SUCOFLEX 126, SUCOFLEX 526V and SUCOFLEX 526S are particularly phase stable when subjected to flexure. High speed digital testing High speed digital chip verification Lowest loss, best signal integrity, dense and space saving PCB connectivity, proven and tested solutions and components High speed digital hardware and system verification Mulitcoax PCB edge/panel mount solutions, custom- ized solutions for Multicoax interconnectivity be- tween systems and modules Automated test equipment Customized Multicaox interfaces at up to 50 GHz, Snap-on interfaces up to 67 GHz, cabling solutions optimized for highest data rates and frequencies. Space Perfect assembly technology Assembly production for space applications in in- house clean room. High reliability Comprehensive series of MIL tests for verification of the out-standing specifications. Minimised outer diameters Space saving wirings with the loss optimised SUCOFLEX 301 space and SUCOFLEX 340 1 3

Advantages of SUCOFLEX® Defense Wide temperature range −55 to +165 °C for most cable types −55 to +125 °C for most connector types Mechanical protection A wide range of ruggedisations are available for most SUCOFLEX cable types. Rugged connectors Insulators and inner conductors fully captivated, patented connector assembly techniques. High packing density Easy connection and disconnection of up to 8 assemblies with multiport connectors according to MIL-C-38999. Naval Chemical stability Thanks to excellent materials (FEP) and inert surfaces. High power performance SUCOFLEX 106 with more than 400 W at 18 GHz CW power capability. Halogen free LSFH jackets for SUCOFLEX assemblies are available. Airborne Vibration stability SUCOFLEX assemblies withstand vibrations involving accelerations up to 100 g without deterioration of their performance. Low weight Unit construction system use of aluminium core conductors for an optimised assembly design with SUCOFLEX 300. Wide frequency range SUCOFLEX from DC up to 50 GHz Minimised losses and excellent stability vs.temperature 1.0 dB/m at 18 GHz for SUCOFLEX 229 < 500 to 800 ppm (−40 to +85 °C) 1 4

Overview SUCOFLEX® Cross reference within product range Interfaces BNC QMA QN 7/16 BMA TNC N PC7 SMA PC3.5 SK PC2.4 Cables 3.50 2.0 SUCOFLEX 301 18 3.65 2.0 SUCOFLEX 101 26.5 40 50 3.65 3.0 SUCOFLEX 550 40 50 4.00 1.7 SUCOFLEX 102 18 18 18 26.5 40 46 4.14 1.6 SUCOFLEX 240 26.5 40 4.14 1.6 SUCOFLEX 340 26.5 40 4.60 1.3 SUCOFLEX 103 4 18 18 18 18 26.5 5.08 1.0 SUCOFLEX 229 18 18 26.5 29 5.08 1.0 SUCOFLEX 329 18 18 26.5 29 5.40 1.2 SUCOFLEX 304 18 18 5.50 1.1 SUCOFLEX 104 6 6 7.5 18 18 18 18 18 26.5 5.50 1.1 SUCOFLEX 126 4 7.5 18 18 18 18 18 26.5 7.70 1.1 SUCOFLEX 526S 18 18 26.5 7.90 0.8 SUCOFLEX 106 6 7.5 18 18 18 18 7.90 0.8 SUCOFLEX 118 18 18 18 9.00 0.34 (5.5) SUCOFLEX 307 5.5 13.0 2.7 SUCOFLEX 526V 26.5 Frequency 1 5 Outer diameter mm Cable attenuation at 18 GHz dB/m

Summary of SUCOFLEX® qualifications The entire SUCOFLEX family is certified to the following standards through testing, analysis or similarity. Temperature, altitude and humidity MIL-STD-810, method 518.1, procedure I Thermal shock MIL-STD-202, method 106, condition B1, 25 cycles, temperature: −54 to 125 °C Mechanical shock MIL-STD-810, method 516.3, procedure I (half-sine), 20 g, 6 to 9 ms, 45 Hz cross over frequency MIL-STD-810, method 516, procedure I (saw-tooth), 40 g saw-tooth pulse of 11 ms duration 3 shocks in each of the six directions Vibration MIL-STD-810, method 519.3, procedure I, figure 514.3-1, (gunfire), 26.5 min. with specified vibration profile MIL-STD-810, method 514.3, procedure I (random), functional: 0.2 g2/Hz, endurance: 0.83 g2/Hz MIL-STD-202; method 204, condition G (sinusoidal), acceleration: 30 g, frequency range: 10 to 2000 Hz, duration: 4 hours in each of three axes Acceleration MIL-STD-810, method 513.3, procedure II, 27 g, 5 min. MIL-STD-810, method 513.3, procedure I, 50 g, 5 min. Chemical resistance British standard 3G100, part 2, section 3, class A Moisture resistance MIL-STD-202, method 106, 10 day exposure Salt fog MIL-STD-810, method 509.2, 48 hours exposure to a 5 % solution Fungus MIL-STD-810, method 508.3 Sand and dust Def. stand. 07-55, part 2, section 4, issue 1, +35 °C, 3 hours Solar radiation MIL-STD-810, method 505, procedure II 1 6

Overview SUCOFLEX® 100 The high performance microwave cable assembly Product description SUCOFLEX 100 series flexible microwave cable assem- blies offer superior electrical and mechanical perfor- mance for static and dynamic applications. This series is a high-end product designed to provide optimal performance up to 50 GHz, where stringent electrical requirements – in particular stability and low loss – are important. Their mechanical and cli- mate resistance properties surpass those of stand- ard flexible cables. This cable type is ideally suited to test and measurement applications (as test leads) and used in aerospace and defence systems. Recommended connectors Product features SF101 / SF550 SMA, SK, PC2.4 • T he cable maintains stable electrical character- SF102 SMA, BMA, N, TNC, PC3.5, SK, PC2.4 istics when exposed to bending and temperature, SF103 BNC, SMA, BMA, N, TNC, PC7, PC3.5 enabling reliable test results SF126 BNC, 7/16, SMA, BMA, QMA, TNC, N, QN, • A balanced range of connectors is available, includ- SF104 PC7, PC3.5 ing types which feature NWA-specific interfaces SF106 7/16, SMA, N, QN, TNC • C an be provided with various ruggedisations to SF118 protect the assembly against different environ- Other connectors available on request mental influences • Available as assembly only Technical data HUBER+SUHNER Operating Temperature Outer Nominal atten. More information cable type frequency range diameter 18 GHz, 25 °C Bending radii Weight see page GHz mini- maxi- mm dB/m static dyn. g/m mum °C mum °C mm mm SUCOFLEX_101 50 −55 +125 3.7 2.0 11 20 36 16 SUCOFLEX_550 50 −55 +125 3.7 3.0 11 20 33 16 SUCOFLEX_550E 50 −40 +85 3.7 3.0 11 20 30 16 SUCOFLEX_102 46 −55 +125 4.0 1.7 12 20 40 20 SUCOFLEX_102_I 46 −40 +85 4.0 1.7 12 20 36 on request SUCOFLEX_103 33 −55 +125 4.6 1.3 13 22 53 24 SUCOFLEX_103_I 33 −40 +85 4.8 1.3 13 20 53 on request SUCOFLEX_104 26.5 −55 +125 5.5 1.1 16 25 84 28 SUCOFLEX_104_I 26.5 −40 +85 6.6 1.1 16 25 82 on request SUCOFLEX_126 26.5 −55 +125 5.5 1.1 16 25 84 34 SUCOFLEX_126_E 26.5 −40 +85 5.5 1.1 16 25 83 34 SUCOFLEX_106 18 −55 +125 7.9 0.8 24 40 145 38 SUCOFLEX_118 18 −55 +125 7.9 0.8 24 40 145 38 SUCOFLEX_106_I 18 −40 +85 8.2 0.8 24 40 146 38 SUCOFLEX_118_I 18 −40 +85 8.2 0.8 24 40 146 38 1 7

SUCOFLEX® 101 / 550 The high performance microwave cable assembly working up to 50 GHz Product description The SUCOFLEX 101 high end cable assemblies are de- signed to provide optimal performance up to 50 GHz were stringent electrical requirements – in particular stability and low loss, are important. Their mechanical and climate resistance properties surpass those of standard flexible cable. Additionally protected by an A ruggedisation, the SUCOFLEX 550E becomes a flexible test and measurement cable up to 50 GHz! Product features • Impedance 50 Ω • Applicable up to 50 GHz Recommended connectors • High stability and low loss SF101 SMA, SK, PC2.4 • Wide range of connectors SF550 • VNA-specific connectors Other connectors available on request Construction SF 101/101E/550/550E SF 101EA/550EA Inner conductor Dielectric Outer conductor Jacket Ruggedisation Cable Outer diameter mm SUCOFLEX_101 CuAg wire LD-PTFE CuAg tape/braid FEP, blue no 3.7 SUCOFLEX_101_E CuAg wire LD-PTFE CuAg tape/braid PUR, blue no 3.7 SUCOFLEX_550 CuAg strand LD-PTFE CuAg tape/braid FEP, blue no 3.7 SUCOFLEX_550E CuAg strand LD-PTFE CuAg tape/braid PUR, blue no 3.7 SUCOFLEX_101_EA CuAg wire LD-PTFE CuAg tape/braid PUR stainless steel/ 7.7 PUR, blue SUCOFLEX_550EA CuAg strand LD-PTFE CuAg tape/braid PUR stainless steel/ 7.7 PUR, blue 1 8

SUCOFLEX® 101 / 550 Assembly types SUCOFLEX SUCOFLEX SUCOFLEX SUCOFLEX SUCOFLEX SUCOFLEX 101 101E 550 550E 101EA 550EA Construction Max. operating frequency GHz 50 50 50 50 50 50 Application static static dynamic dynamic static dynamic Velocity of propagation % 77 77 77 77 77 77 Weight g/m 36 33 33 30 114 111 Min. bending radius static mm 11 11 11 11 20 20 Min. bending radius repeated mm 20 20 20 20 40 40 Temperature range °C −55 to +125 −40 to +85 −55 to +125 −40 to +85 −40 to +85 −40 to +85 Crush resistance kN/m 8 8 8 8 80 80 Inner conductor solid wire solid wire strand low strand low solid wire strand low loss loss loss Dielectric LD-PTFE LD-PTFE LD-PTFE LD-PTFE LD-PTFE LD-PTFE Outer conductor tape/braid tape/braid tape/braid tape/braid tape/braid tape/braid Jacket FEP PUR FEP PUR PUR PUR Ruggedisation no no no no stainless stainless steel/ PUR steel/PUR Outer diameter mm 3.7 3.7 3.7 3.7 7.7 7.7 Screening effectiveness dB > 90 > 90 > 90 > 90 > 90 > 90 (up to 18 GHz) Phase stability vs. flexure °el/GHz < 1.2 < 1.2 < 0.35 < 0.35 < 1.2 < 0.35 (360°, diameter 40 mm) Phase stability vs. tempera- ppm < 1500 < 1500 < 1500 < 1500 < 1500 < 1500 ture (−40 to +85 °C ) Assembly phase matching °el/GHz ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 tolerances Cable attenuation at 25 °C dB/m see graph see graph see graph see graph see graph see graph Insertion loss stability vs. dB ± 0.2 ± 0.2 ± 0.1 ± 0.1 ± 0.2 ± 0.1 bending Insertion loss stability vs. %/°C < 0.2 < 0.2 < 0.2 < 0.2 < 0.2 < 0.2 temperature Insertion loss stability vs. dB ± 0.1 ± 0.1 ± 0.1 ± 0.1 ± 0.1 ± 0.1 shaking Power handling watt see graph see graph see graph see graph see graph see graph 1 9

SUCOFLEX® 101 / 550 Attenuation (nominal values at +25 °C ambient temperature) 6 SF 101 SF 101E SF 101EA SF 550 5 SF 550E SF 550EA 4 3 2 1 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 Frequency GHz Power handling (maximum values at 25 °C ambient temperature and sea level) 400 SF 101 SF 550 SF 101E 350 SF 550E SF 101EA SF 550EA 300 250 200 150 100 50 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 Frequency GHz 2 0 Power handling Watts Attenuation dB/m